Friction drive material handling system including composite beam and method of operating same

ABSTRACT

A material handling system includes a composite beam including an upper rail and a lower track connected through a plurality of spaced apart transverse members. A trolley includes an upper set of wheels and a lower set of wheels. The lower set of wheels is received within two parallel channels defined by the lower track. A drive tube is positioned between the upper rail and the lower track such that the upper set of wheels are in frictional engagement with the drive tube. A drive system is configured to rotate the drive tube.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of U.S. patentapplication Ser. No. 12/151,881, filed May 9, 2008.

TECHNICAL FIELD

The present disclosure relates generally to a material handling system,and more particularly to a friction drive material handling systemincluding a composite beam.

BACKGROUND

During a manufacturing process, a product is typically advanced througha plurality of manufacturing stations of a manufacturing chain.Specifically, the product is transported through each of themanufacturing stations along an article transportation device. At eachmanufacturing station, a specific one of a plurality of tasks in themanufacturing process is performed. All equipment and other componentsnecessary to perform the assigned task are positioned, and oftenpermanently affixed, at each manufacturing station. As a result, anddependent upon the number of tasks and the complexity of themanufacturing process, a manufacturing chain is typically a largestructure that is permanently situated inside a manufacturing facility.

At least partially as a result of its permanency, a manufacturing chainis typically inflexible, such that modifying, removing, or replacing themanufacturing chain may be an expensive and time-consuming process.Therefore, even minor improvements to the manufacturing process, suchas, for example, changes to the equipment positioned at onemanufacturing station, may be too expensive and time consuming toimplement. Further, if the manufacturing process performed by themanufacturing chain becomes unnecessary, it may not be feasible to alterthe manufacturing chain to perform a different manufacturing process.Ultimately, the manufacturing chain may only be cost effective inperforming the specific manufacturing process for which it was designed.As a result, the significant amount of costs and efforts to design andconstruct the manufacturing chain may be wasted.

Another drawback with conventional manufacturing chains involves thearticle transportation system along which the products are transported.Since the products are typically carried along one articletransportation device having a single driving source, such as a commonmonorail conveyor, the entire manufacturing chain must be stopped inorder to correct a problem occurring at any point along themanufacturing chain. Power and free conveyors offer one solution byallowing carriers to be routed off of the main line, such as if a defectis identified, but still provide continuous movement of the main line.In either case, stopping the main line can result in significant downtime and, therefore, reduced efficiency and, ultimately, throughput ofthe manufacturing chain. This may further increase process time formanufacturing processes that already require a significant amount oftime. For example, it is known that a drying or curing stage of a paintprocess may require a significant amount of time, thus greatlyincreasing the minimal process time for the manufacturing process.

U.S. Pat. No. 6,120,604 teaches a powder coating chain having aplurality of conveyors for transporting parts through a plurality ofprocessing areas. Specifically, each processing area includes a separatemotor driven conveyor, sensors for providing information on conditionswithin the processing area, and a control circuit coupled to both thesensors and an operator interface. A user may manipulate the operatorinterface to monitor sensed conditions within each processing area.Although the reference suggests an aspect of modularity that may offercertain limited benefits, it does not contemplate improvements to theoverall process flow within the manufacturing chain. In fact, thereference does not disclose modifications to the exemplary high-speedblank powder coating process, but rather seeks to quickly identify asource of a mechanical problem associated with the process. As should beappreciated, there is a continuing need for manufacturing chainsproviding improved quality and efficiency with respect to amanufacturing process. In addition, there is a continuing need formanufacturing chains, or manufacturing stations thereof, that may bemore easily modified, removed, or replaced.

The present disclosure is directed to one or more of the problems setforth above.

SUMMARY OF THE DISCLOSURE

In one aspect, a material handling system includes a composite beamincluding an upper rail and a lower track connected through a pluralityof spaced apart transverse members. A trolley includes an upper set ofwheels and a lower set of wheels. The lower set of wheels is receivedwithin two parallel channels defined by the lower track. A drive tube ispositioned between the upper rail and the lower track such that theupper set of wheels are in frictional engagement with the drive tube. Adrive system is configured to rotate the drive tube.

In another aspect, a method of operating a material handling systemincludes a step of transporting a trolley having an upper set of wheelsand a lower set of wheels along the material handling system, at leastin part, by supporting the lower set of wheels of the trolley within twoparallel channels defined by a lower track. The upper set of wheels ofthe trolley is frictionally engaged with a drive tube. The drive tube isrotated to move the lower set of wheels within the two parallelchannels. A weight carried by the trolley is supported with a compositebeam including an upper rail and the lower track connected through aplurality of spaced apart transverse support members.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic perspective view of a manufacturing chain,according to the present disclosure;

FIG. 2 is a diagrammatic perspective view of a manufacturing module ofthe manufacturing chain of FIG. 1, according to the present disclosure;

FIG. 3 is a side diagrammatic view of an alternative embodiment of themanufacturing module of FIG. 2, according to the present disclosure;

FIG. 4 is a side diagrammatic view of an alternative embodiment of themanufacturing module of FIG. 2 including a first vertical lift device,according to the present disclosure;

FIG. 5 is a side diagrammatic view of an alternative embodiment of themanufacturing module of FIG. 2 including a second vertical lift device,according to the present disclosure;

FIG. 6 is a block diagram of one embodiment of a control system foroperating the manufacturing chain of FIG. 1, according to the presentdisclosure;

FIG. 7 is a block diagram of an alternative embodiment of a controlsystem for operating the manufacturing chain of FIG. 1, according to thepresent disclosure; and

FIG. 8 is a perspective view of one embodiment of a modular materialhandling system, according to the present disclosure;

FIG. 9 a is a cross-sectional view of a first exemplary composite beamfor use with the modular material handling system of FIG. 8, accordingto the present disclosure;

FIG. 9 b is a cross-sectional view of a second exemplary composite beamfor use with the modular material handling system of FIG. 8, accordingto the present disclosure; FIG. 9 c is a cross-sectional view of a thirdexemplary composite beam for use with the modular material handlingsystem of FIG. 8, according to the present disclosure;

FIG. 10 is a partially exploded view of a manufacturing module includingthe modular material handling system of FIG. 8, according to the presentdisclosure;

FIG. 11 a is plan view of a modular material handling system including adual track assembly, according to the present disclosure;

FIG. 11 b is a side diagrammatic view of a trolley assembly configuredto support a carrier along the dual track assembly of FIG. 11 a,according to the present disclosure;

FIG. 12 is a side diagrammatic view of a buffer, according to thepresent disclosure;

FIG. 13 is a block diagram of a first line, according to the presentdisclosure; and

FIG. 14 is a plan view of a second line, according to the presentdisclosure.

DETAILED DESCRIPTION

An exemplary embodiment of a manufacturing chain 10 is shown generallyin FIG. 1. The manufacturing chain 10 may be disposed within amanufacturing area 12, such as, for example, a manufacturing areadefined by a building 14. According to one embodiment, the manufacturingchain 10 may be secured to, and positioned above, a planar floor 16 ofthe manufacturing area 12. However, numerous locations and arrangementsare contemplated for the manufacturing chain 10. According to theexemplary embodiment, the manufacturing chain 10 may be used to performa paint process, such as, for example, a powder coating process, and,therefore, may also be referred to as a paint line. Although a paintprocess is described, however, it should be appreciated that themanufacturing chain 10 may be designed to perform any of a variety ofmanufacturing processes.

The manufacturing chain 10, also referred to as a modular manufacturingchain, may include several modular manufacturing stations, such thateach modular manufacturing station is configured to perform at least onetask in the manufacturing process. Specifically, and according to oneexample, the manufacturing chain 10 may include a wash station 18, ablow off station 20, an inspection station 22, a paint applicationstation 24, a curing station 26, and an unload station 28. Although sixmodular manufacturing stations 18, 20, 22, 24, 26, and 28 are shown, itshould be appreciated that the manufacturing chain 10 may include anynumber of modular manufacturing stations necessary to perform thedesignated manufacturing process. It should also be appreciated that thepaint process, as described herein, has been simplified for ease ofexplanation, and is in no way meant to be limited to the specific tasksdescribed.

The modular manufacturing stations 18, 20, 22, 24, 26, and 28 may bepositioned in series, as shown, or the manufacturing chain 10 mayinclude one or more of the modular manufacturing stations 18, 20, 22,24, 26, and 28 positioned in parallel, as dictated by the specific tasksof the manufacturing process. Further, the modular manufacturingstations 18, 20, 22, 24, 26, and 28 may include equipment, and othercomponents, necessary to accomplish the task to be performed at therespective one of the modular manufacturing stations 18, 20, 22, 24, 26,and 28. It should be appreciated that multiple tasks may be performed atone modular manufacturing station or, alternatively, a more complex taskmay be performed over a plurality of modular manufacturing stations.Ultimately, one or more tasks may be performed on an article, orproduct, as it is transported through the modular manufacturing stations18, 20, 22, 24, 26, and 28 along an article transportation system 30,described later in greater detail.

The equipment and other components necessary to perform a task at arespective one of each of the modular manufacturing stations 18, 20, 22,24, 26, and 28 may be supported by a framework or, more specifically, amanufacturing module 32. For example, the manufacturing chain 10 mayinclude a plurality of manufacturing modules 32 positioned andconfigured to accommodate the modular manufacturing stations 18, 20, 22,24, 26, and 28. As shown in the embodiment of FIG. 1, the manufacturingmodules 32 may be positioned in series, as dictated by the modularmanufacturing stations 18, 20, 22, 24, 26, and 28. However, the size andgeometry of the manufacturing chain 10, comprising the manufacturingmodules 32, may include any of a variety of possible sizes andconfigurations, such as, for example, an “L” shaped configuration or a“U” shaped configuration. Further, although FIG. 1 illustrates exactlyone of the modular manufacturing stations 18, 20, 22, 24, 26, and 28associated with each manufacturing module 32, it should be appreciatedthat each manufacturing module 32 may support more than one of themodular manufacturing stations 18, 20, 22, 24, 26, and 28.

According to the exemplary embodiment, the wash station 18 may beconfigured to perform a wash and/or rinse task of the paint process.Specifically, the wash station 18 may include a water tank 34, supportedby the manufacturing module 32, for supplying water, or a solventmixture, to the wash station 18. Alternatively, however, water may besupplied directly to the wash station 18 from a utility infrastructureof the building 14 or, alternatively, from an external utilityconnection 36 disposed outside the manufacturing area 12 and connectedto the manufacturing chain 10 via a conduit 38. The external utilityconnection 36 may, therefore, include a source of water or,alternatively, may include a source of another utility, such as, forexample, electric power or data.

According to the current embodiment, the conduit 38 may provide water toa utility transfer module 40 supported by the manufacturing module 32.The utility transfer module 40 may be configured to transfer a utility,such as, for example, electric power, fluid, or data, through themanufacturing module 32. The utility may be used at the wash station 18and, further, may be transferred to a contiguous manufacturing module32. For example, each of the other manufacturing modules 32 may includeutility transfer modules 40, such that a utility may be supplied at onemanufacturing module 32 and used at another. Specifically, eachmanufacturing module 32 may receive a utility from a precedingmanufacturing module 32 of the manufacturing chain 10, and may transferthe utility to a succeeding manufacturing module 32.

The wash station 18 may further include a water pump 42 for circulatingthe water or solvent mixture through the wash station 18 and/orpressurizing the water or solvent mixture. According to one embodiment,the water or solvent mixture may be directed through a plurality ofwater nozzles 44, such that the water nozzles 44 are configured to sprayan article as it passes through the wash station 18 to remove anyforeign substances deposited on the article. Such foreign substances mayinclude, for example, grease, dirt, dust, oils, or any other substancesthat may interfere with the paint application process. The wash station18 may also include a plurality of water barrier panels 46 forpreventing the water or the solvent mixture from escaping the washstation 18, and a drain system for returning the used water or thesolvent mixture to the water tank 34. It should be appreciated that thewash station 18 may include any equipment useful in removing foreignsubstances from an article before paint, such as, for example, powderedpaint, is applied.

The blow off station 20 may be configured to remove any water or solventmixture remaining on the article after the article passes through thewash station 18. Specifically, the blow off station 20 may include a fan48, or pump, for pressurizing air and a plurality of air nozzles 50 fordirecting the pressurized air toward the article. Either or both of thefan 48 and air nozzles 50 may be supported by the manufacturing module32. Further, the blow off station 20 may include a hose (not shown)available to an operator for manually directing pressurized air towardthe article. According to one embodiment, pressurized air may beprovided via the utility transfer module 40. Specifically, pressurizedair may be supplied to the utility transfer module 40 directly from asource, or indirectly via the utility transfer module 40 of a contiguousmanufacturing module 32.

Air barrier panels 52, or walls, may also be provided at the blow offstation 20 for preventing pressurized air blown from the air nozzles 50from interfering with activities or equipment outside of the blow offstation 20. After the water or solvent mixture is sufficiently removedfrom the article at the blow off station 20, the article may betransported to the inspection station 22, which may provide a locationfor an operator 54 to inspect the article. The inspection may, forexample, involve visual, physical, or chemical analyses to determine thepresence of any remaining impurities on the surface of the article.

After inspection, the article may be transported along the articletransportation system 30 to the paint application station 24. The paintapplication station 24 may include a piece of paint applicationequipment 56 for coating the article with paint, such as, according toone example, a powdered paint. The paint application station 24 mayfurther include a plurality of paint barrier panels 58 for restrictingthe paint to the confines of the paint application station 24. Either orboth of the paint application equipment 56 and the paint barrier panels58 may be supported by the manufacturing module 32. Alternatively,however, the paint application equipment 56 and the paint barrier panels58 may be secured to the planar floor 16. As should be appreciated, theequipment used at the paint application station 24 may vary, dependingon the type of paint used and the application process that isimplemented. For example, the paint may be sprayed onto the article or,alternatively, the article may be immersed in a tank containing paint.

From the paint application station 24, the article may be transported tothe curing station 26. The curing station 26 may be configured to heator otherwise cure the coating of freshly applied paint. According to oneembodiment, the curing station 26 may include a plurality of infraredheaters 60, which may contain a plurality of infrared heater lamps 62for generating the heat necessary for causing the coating of paint onthe article to cure. According to one embodiment, the infrared heaters60 may be portable. For example, one or more sets of rollers 64 may beprovided to facilitate movement of the infrared heaters 60 from onelocation, such as a storage location, and into the illustrated positionrelative to the paint application station 24. It should be appreciatedthat “portable” equipment, as used herein, may refer to any equipment orcomponent that may not be characterized as a fixture or otherwisepermanently attached component. It should also be appreciated that anyequipment useful in making the coating of paint applied to the articlepermanent is contemplated for use at the curing station 26.

For simplicity, the exemplary paint process is described as having onepaint application station 24; however, it should be appreciated that apaint process may often include coating the article with multiplecoatings of paint. As a result, the manufacturing chain 10 may includeadditional paint applications stations 24 and, if necessary,manufacturing modules 32 to accommodate such a process. Ultimately,after the desired number of paint coatings are applied to the article,the article may be transported to the unload station 28. At the unloadstation 28, the article may be removed from the manufacturing chain 10or, more specifically, the article transportation system 30 by anoperator 66. After passing through the manufacturing chain 10, it iscontemplated that the article may be transported to anothermanufacturing chain for further processing, if desired. According to oneembodiment, the article may be routed to a buffer area before passing toanother manufacturing chain. Alternatively, the article may be taken toa storage location for storage, or to a transportation vehicle fordelivery to a customer.

Turning now to FIG. 2, an exemplary manufacturing module 32 forsupporting one or more of the modular manufacturing stations 18, 20, 22,24, 26, and 28 of FIG. 1 is shown in greater detail. Specifically, themanufacturing module 32 may consist of a plurality of beams, such astubular beams, forming a framework or skeleton 80. According to oneembodiment, the skeleton 80 may include a plurality of verticallyaligned support beams 82, 84, 86, and 88 attached to the planar floor 16using support plates 90, 92, 94, and 96, respectively. Although a boltedconnection is shown, it should be appreciated that the support beams 82,84, 86, and 88 and/or support plates 90, 92, 94, and 96 may be attachedto the planar floor 16 using any secure connection.

The vertically aligned support beams 82, 84, 86, and 88 may beinterconnected using a plurality of additional support beams, such ashorizontally aligned beams 98, 100, 102, and 104. The horizontallyaligned support beams 98, 100, 102, and 104 and vertically alignedsupport beams 82, 84, 86, and 88 may define an entry 106 and an exit 108of the manufacturing module 32, and may provide structural support forone or more modular manufacturing stations, such as the modularmanufacturing stations 18, 20, 22, 24, 26, and 28 of FIG. 1. As such,the support beams 82, 84, 86, 88, 98, 100, 102, and 104 may befabricated from steel, carbon composites, or any other material known inthe art suitable for providing the desired support. According to oneembodiment, it may be desirable to utilize a relatively lightweightmaterial to ease the transport and/or construction of the manufacturingmodule 32.

Additionally, it may be desirable to allow for expansion and/orcontraction of one or more of the support beams 82, 84, 86, 88, 98, 100,102, and 104. Such expansion and/or contraction may further ease thetransport and/or construction of the manufacturing module 32, and mayalso allow for a customized size and/or shape of each manufacturingmodule 32. For example, the desired size and/or shape of themanufacturing module 32 may depend upon a number of factors including,but not limited to, the number of modular manufacturing stations, suchas modular manufacturing stations 18, 20, 22, 24, 26, and 28, disposedwithin the manufacturing module 32.

To facilitate adjustment, one or more of the support beams 82, 84, 86,88, 98, 100, 102, and 104 may include a hollow tubular portion and apiston portion. For example, vertically aligned support beam 82 is shownhaving a tubular portion 82 a and a piston portion 82 b. As should beappreciated, the piston portion 82 b may be slidably received within thetubular portion 82 a and locked at a desired length. Locking may beaccomplished using any known fastening devices, such as, for example,bolts, screw, pins, or spring-actuated bearings. Alternatively, however,each of the support beams 82, 84, 86, 88, 98, 100, 102, and 104 may befabricated to various desired lengths, as dictated by the design of themanufacturing module 32. According to one embodiment, it may bedesirable to expand and/or contract only the vertically aligned supportbeams 82, 84, 86, and 88.

Although the support beams 82, 84, 86, 88, 98, 100, 102, and 104 areillustrated as forming a cubic shape, they may, alternatively, bepositioned to form any shape conducive to the specific manufacturingprocess being performed. Additionally, the number of support beams 82,84, 86, 88, 98, 100, 102, and 104 utilized to form the skeleton 80 mayvary depending upon the shape of the manufacturing module 32. Thesupport beams 82, 84, 86, 88, 98, 100, 102, and 104 of the manufacturingmodule 32 may be secured together by mechanical fasteners, welds, or anyother devices known in the art that are used to secure components.Additionally, the skeleton 80 of the manufacturing module 32 may beattached to the framework of a contiguous manufacturing module 32 usingsimilar fasteners. Alternatively, however, the manufacturing module 32may be positioned adjacent a contiguous manufacturing module 32 and maynot be attached thereto. A “contiguous” manufacturing module, as usedherein, may refer to a manufacturing module, such as manufacturingmodule 32, positioned in close proximity to another manufacturingmodule, such as, for example, a preceding or succeeding manufacturingmodule in the manufacturing chain 10.

One or more of the support beams 82, 84, 86, 88, 98, 100, 102, and 104of the skeleton 80 may support the utility transfer module 40. Theutility transfer module 40 may be configured to transfer at least one ofelectric power, fluid, and data through the manufacturing module 32.Specifically, the utility transfer module 40 may transfer and/or provideelectric power, water, compressed air, gas, or other utilities to theone or more modular manufacturing stations, such as modularmanufacturing stations 18, 20, 22, 24, 26, and 28, supported by themanufacturing module 32. According to one embodiment the utilitytransfer module 40 may include a collection of wires, cables, or otherconduits capable of transferring one or more utilities.

The utility transfer module 40 may include an external port 110 forengaging an external utility connection, such as, for example, theexternal utility connection 36 of FIG. 1. Although the external utilityconnection 36 is positioned outside the building 14, it should beappreciated that the external utility connection 36 may be positionedwithin the building 14, such as within the manufacturing area 12.According to one embodiment, the external utility connection 36 includesa utility source, such as, for example, an electric power grid, agenerator, a battery, a compressed air tank, a hydraulic tank, and/or awater supply. It should be appreciated that the external utilityconnection 36 may include any source of a utility that is utilized bythe manufacturing chain 10. Accordingly, each utility transfer module 40may include multiple external ports 110, depending on the number ofutility sources to be engaged.

Each utility transfer module 40 may also include an entry port 112 forengaging a utility transfer module 40 of a preceding manufacturingmodule 32, and an exit port 114 for engaging a utility transfer module40 of a succeeding manufacturing module 32. It should be appreciatedthat the entry port 112 of the utility transfer module 40 of the firstmanufacturing module 32 in the manufacturing chain 10 may remain unusedand, similarly, the exit port 114 of utility transfer module 40 of thelast manufacturing module 32 may remain unused. Such ports, however, maybecome necessary, such as, for example, when an additional manufacturingmodule 32 is added to the manufacturing chain 10.

Additionally, the utility transfer module 40 may include one or moreequipment ports, such as a first equipment port 116, for providing autility to the one or more modular manufacturing stations, such as themodular manufacturing stations 18, 20, 22, 24, 26, and 28, of themanufacturing module 32. According to a more general example,manufacturing module 32 may support a first modular manufacturingstation 118 that is configured to perform at least one task of amanufacturing process. Accordingly, the first modular manufacturingstation 118 may include equipment, and other systems and/or components,necessary to accomplish the task to be performed. Specifically, andaccording to one example, the first modular manufacturing station 118may include a piece of manufacturing equipment 120, an articletransportation device 122 representing a portion of the articletransportation system 30 corresponding to the station 118, and a stationcontrol system 124. Although the manufacturing equipment 120 isexemplified as a plurality of air nozzles, similar to air nozzles 50, itshould be appreciated that any manufacturing equipment useful inperforming a manufacturing task is contemplated.

One or more of the manufacturing equipment 120, the articletransportation device 122, and the station control system 124 mayreceive utilities, such as electric power, fluid, and data, from theutility transfer module 40. For example, the manufacturing equipment 120may include a conduit 126 having a quick connect coupling member 128 forengaging the first equipment port 116. Similarly, the articletransportation device 122 may include a conduit 130 having a quickconnect coupling member 132 for engaging a second equipment port 134 ofthe utility transfer module 40. In addition, the station control system124 may include conduit 136 having a quick connect coupling member 138for engaging a third equipment port 140 of the utility transfer module40.

It should be appreciated that any of the ports or connections describedherein, such as, for example, ports 110, 112, 114, 116, 134, and 140,may embody electrical outlets, quick connect coupling members, or anyother known utility interfaces. In addition, each of the quick connectcoupling members 128, 132, and 138 may embody any appropriate utilityinterface for engaging one or more of the ports 110, 112, 114, 116, 134,and 140. It should also be appreciated that quick connect couplingmembers may enable relatively quick and easy assembly and/or disassemblyof the manufacturing stations, such as modular manufacturing stations18, 20, 22, 24, 26, and 28, and/or first modular manufacturing station118. Additional benefits may be recognized by utilizing common, oruniversal, interfaces throughout the entire manufacturing chain 10.

According to one embodiment, the utility transfer module 40 may besecured to one of the support beams 82, 84, 86, 88, 98, 100, 102, and104, such as support beam 102, using one or more mounting devices 142.Mounting devices 142 may, for example, include hooks, latches, sockets,or any other devices capable of securing the utility transfer module 40to one or more of the support beams 82, 84, 86, 88, 98, 100, 102, and104. Alternatively, however, the utility transfer module 40 may bepositioned within a hollow portion, such as, for example, a centralportion, of one or more of the tubular support beams 82, 84, 86, 88, 98,100, 102, and 104. It should be appreciated that the utility transfermodule 40 may be supported by and/or secured to any number of thesupport beams 82, 84, 86, 88, 98, 100, 102, and 104, as necessary totransfer a utility through and/or provide a utility to the manufacturingmodule 32.

Turning now to FIG. 3, an alternative embodiment of a manufacturingmodule 32 is shown. Specifically, one or more of the manufacturingmodules 32 may include a second modular manufacturing station 160disposed between the entry 106 and the exit 108 of the manufacturingmodule 32. The second modular manufacturing station 160 may includesimilar systems and/or components as the first modular manufacturingstation 118. Specifically, the second modular manufacturing station 160may include at least one piece of manufacturing equipment 120, anarticle transportation device 122 representing a portion of articletransportation system 30 corresponding to the second modularmanufacturing station 160, and a station control system 124.

It should be appreciated that each of the systems and/or components ofthe second modular manufacturing station 160 may also receive a utilityfrom the utility transfer module 40 in a manner similar to thatdescribed above. It should further be appreciated that either or both ofthe first and second modular manufacturing stations 118 and 160 may berepresentative of the modular manufacturing stations 18, 20, 22, 24, 26,and 28 of FIG. 1. Accordingly, each of the modular manufacturingstations 18, 20, 22, 24, 26, and 28 may generally include one or more ofthe manufacturing equipment 120, article transportation device 122, andstation control system 124.

Each article transportation device 122 may include a friction drivesystem having one or more sets of carrier tracks, such as carrier tracks162, along which a carrier 164 may be transported. It should beappreciated that the one or more sets of carrier tracks 162 may define atransportation path 166 through a manufacturing chain, such as themanufacturing chain 10 of FIG. 1. Friction drive systems are known, andmay generally include one or more hanger rails 168 fixedly attached tothe skeleton 80 for supporting one or more support rails 170. At leastone of the support rails 170 may provide support for a drive shaft 172that may be mechanically coupled to a drive system 174.

The drive system 174 may, for example, include an electric, hydraulic,or pneumatic motor, and may further include a transmission and controls,as necessary, for driving the drive shaft 172 at a desired speed and ina desired direction. For example, the drive shaft 172 may be rotated ina first direction for frictionally engaging wheels of the carrier 164such that the carrier 164 is moved in a forward transport direction,represented by arrow “F”. Alternatively, however, the drive shaft 172may be rotated, by the drive system 174, in an opposite direction forfrictionally engaging wheels of the carrier 164 to move the carrier 164in a reverse transport direction “R” that is opposite the forwardtransport direction “F.” A similar friction drive system may be providedby OCS IntelliTrak, Incorporated of Cincinnati, Ohio.

Although a friction drive system is described, however, it should beappreciated that a variety of material handling systems may be used. Forexample, an air balancer, a series of hoists, an electrified monorail,or any other device capable of moving an article through themanufacturing chain 10 are also contemplated. Further, it should beappreciated that carriers, such as carriers 164, may include any devicescapable of gripping an article to be conveyed through the manufacturingchain 10. Exemplary carriers may, for example, include hooks, clamps,latches, or any other devices capable of temporarily grasping thearticle. Although a single carrier 164 is depicted for transporting anarticle, it should be appreciated that multiple carriers may benecessary for transporting the article, depending on the size and weightof the article.

It is also contemplated that the article transportation system 30 may besubstituted with a chain, belt, or any other device that may conveycarriers 164 through the manufacturing chain 10. According to oneembodiment, the article transportation system 30 may be mounted to theplanar floor 16 and/or contain a transport device, such as, for example,a conveyor belt to convey the article through the manufacturing chain10. Preferably, however, the article transportation devices 122 thatdefine the article transportation system 30 may each include at leastone drive system 174, or similar means, for facilitating independentmovement of the carrier 164 within the respective one of themanufacturing stations 118 and 160.

Each station control system 124 may be configured to control operationof at least one of the article transportation device 122 and themanufacturing equipment 120 of the respective one of the modularmanufacturing stations 118 and 160. Specifically, the station controlsystem 124 may be in communication with the article transportationdevice 122 or, more specifically, the drive system 174, and may beconfigured to issue an operation signal, such as, for example, a forwardsignal, a reverse signal, and a stop signal. The forward signal maycorrespond to the forward transport direction “F,” the reverse signalmay correspond to the reverse transport direction “R,” and the stopsignal may correspond to a stationary position. It should be appreciatedthat the stationary position may represent a state in which the carrier164 is not driven in either of the forward transport direction “F” orthe reverse transport direction “R”.

According to one embodiment, the carrier 164 of the first modularmanufacturing station 118 may be driven in the forward transportdirection “F” while the carrier 164 of the second modular manufacturingstation 160 is simultaneously driven in the reverse transport direction“R” or, alternatively, remains stationary. According to a specificexample, it may be desirable to move the carrier 164 of the secondmodular manufacturing station 160 in the reverse transport direction “R”relative to the manufacturing equipment 120. As should be appreciated,continuous forward and reverse movement relative to the manufacturingequipment 120 may prove beneficial in a variety of tasks of amanufacturing process, including, but not limited to, a wash task and ablow off task, as described above. According to an additional example,it may be desirable to stop the carrier 164 of the second modularmanufacturing station 160, such as in response to the identification ofa defect, while one or more other carriers 164 continue to move. Avariety of defects are contemplated, such as, for example, defectsresulting from process problems and/or equipment failures.

Each modular manufacturing station 118 and 160 may also include one ormore position tracking devices. According to one embodiment, a firstposition tracking device 176, a second position tracking device 178, anda third position tracking device 180 are each positioned for detecting aposition of the carrier 164 as it is transported through the station 118and 160. Position tracking devices 176, 178, and 180 are known, and mayinclude, for example, position sensors, proximity switches, bar codereaders, or any other devices capable of detecting a position of thecarrier 164. In addition, the position tracking devices 176, 178, and180 may be supported by the skeleton 80, the article transportationdevice 122, or may be otherwise positioned. Although three positiontracking devices 176, 178, and 180 are shown, it should be appreciatedthat any number of position tracking devices may be used, as dictated bythe manufacturing process.

Each station control system 124 may also be in communication with theposition tracking devices 176, 178, and 180, and may receive signalsfrom one or more of the position tracking devices 176, 178, and 180 thatare indicative of first, second, and third detected positions of thecarrier 164. Each station control system 124 may also be configured toissue one or more operation signals, such as, for example, the forwardsignal, reverse signal, and stop signal, to the article transportationdevice 122 based, at least in part, on one of the detected carrierpositions. According to one example, it may be desirable for the stationcontrol system 124 to issue the stop signal to the articletransportation device 122 when the carrier 164 has reached apredetermined position relative to the manufacturing equipment 120.After a predetermined period of time, for example, the station controlsystem 124 may then issue the forward signal to the articletransportation device 122. Further, the station control system 124 mayissue one or more operation signals to the manufacturing equipment 120based, at least in part, on one of the detected carrier positions.

Turning now to FIG. 4, an alternative embodiment of a manufacturingmodule 32 is shown. Specifically, the transportation path 166 defined bythe carrier tracks 162 may include a vertical discontinuity 200. Itshould be appreciated that, according to one example, the verticaldiscontinuity 200 may occur where the transportation path 166 includes afirst transport height 202 that is vertically spaced from a secondtransport height 204. Specifically, the two sets of carrier tracks 162of the first modular manufacturing station 118 may be positioned at thefirst transport height 202, while the carrier tracks 162 of the secondmodular manufacturing station 160 are positioned at the second transportheight 204. Such a discontinuity along the transportation path 166 mayoccur as a result of the design of the manufacturing chain 10, asdictated by a topography of the manufacturing area 12 or a variety ofother factors. Additionally, it may be desirable to alter the height ofthe transportation path 166 relative to the manufacturing equipment 120.

A first vertical lift device 206 may be provided for moving one of thesets of carrier tracks 162 in a vertical direction relative to thetransportation path 166. Specifically, the first vertical lift device206 may be configured to move one of the sets of carrier tracks 162,adjacent the vertical discontinuity 200, from the first transport height202 to the second transport height 204. Vertical lift devices, such asvertical lift device 206, are known, and may include, for example,electric or pneumatic lifts, and, as such, may receive any necessaryutilities from the utility transfer module 40. In addition, the firstvertical lift device 206 may be supported by and/or secured to theskeleton 80 of the manufacturing module 32.

A control system, such as, for example, the station control system 124,may also be provided for controlling operation of the first verticallift device 206. Specifically, and according to one embodiment, thestation control system 124 may also be in communication with the firstvertical lift device 206, and may be configured to issue operationsignals thereto, such as, for example, a raise signal and a lowersignal. For example, the first vertical lift device 206 may beconfigured to move the carrier tracks 162 from the first transportheight 202 to the second transport height 204 in response to the raisesignal. In addition, the first vertical lift device 206 may beconfigured to move the carrier tracks 162 from the second transportheight 204 to the first transport height 202 in response to the lowersignal.

Further, the station control system 124 may be configured to issue theraise signal and/or the lower signal in response to a carrier positionthat is detected by one of the position tracking devices 176, 178, and180. Specifically, and according to one example, it may be desirable toissue the raise signal when it is determined that the carrier 164 hasreached a predetermined position relative to the carrier tracks 162.After the carrier tracks 162 have been raised, the carrier 164 maycontinue to be transported along the transportation path 168 at thesecond transport height 204, such as by the drive system 174.

The transportation path 168 may include additional verticaldiscontinuities, such as, for example, a second vertical discontinuity210, shown in FIG. 5. A second vertical lift device 212, similar tofirst vertical lift device 206, may, therefore, be provided to advancethe carrier 164 through the second vertical discontinuity 210.Specifically, the second vertical lift device 212 may move the carriertracks 162 from the second transport height 204 to the first transportheight 202, such as in response to the lower signal issued from thestation control system 124. It should be appreciated that the stationcontrol system 124 may issue the lower signal in response to a carrierposition detected by one of the position tracking devices 176, 178, and180. It should also be appreciated that any number of vertical liftdevices, such as lift devices 206 and 212 that may be manually orautomatically operated, may be used throughout the manufacturing chain10 to accommodate vertical discontinuities and/or to move one of thecarriers 164 in a vertical direction relative to the manufacturingequipment 120.

According to one embodiment, it may be desirable to incorporate one ormore vertical lift devices, such as the lift devices 206 and 212, intothe manufacturing chain 10 to accommodate manufacturing equipment 120positioned above the planar floor 16. Specifically, the manufacturingchain 10 may include one or more pieces of manufacturing equipment 120that traditionally were positioned below the planar floor 16, such as,for example, tanks or baths. For ease of deployment, the manufacturingchain 10 may position all equipment 120, including such tanks or baths,above ground and, therefore, may advance the carriers 164 through themanufacturing chain 10 and relative to the manufacturing equipment 120using one or more vertical lift devices 206 and 212.

It should be appreciated that utilizing an article transportation device122 having at least one of reverse, stop, and lift capabilities mayallow a decrease in size and/or output capacity of the manufacturingequipment 120. For example, a conventional curing station may require arelatively large infrared heater capable of generating a large amount ofheat. Specifically, the infrared heater may be sized to adequately curea coating of paint on an article as it passes through the curing stationat a speed equal to an overall line speed. However, the articletransportation device 120, as described herein, may stop and/or reversethe article as it passes through the curing station 26. Therefore, themanufacturing equipment 120 or, more specifically, the infrared heatersused therein may have a lower heat output requirement. As a result,significant cost savings relative to the manufacturing equipment 120 maybe recognized.

An exemplary control system 220 for the manufacturing chain 10 is showngenerally in FIG. 6. Specifically, the control system 220 may includethe station control systems 124 of each modular manufacturing stationwithin the manufacturing chain 10, such as the modular manufacturingstations 18, 20, 22, 24, 26, and 28. It should be appreciated that themodular manufacturing stations 18, 20, 22, 24, 26, and 28 of FIG. 1 mayinclude configurations similar to any of the embodiments of the firstand second modular manufacturing stations 118 and 160 of FIGS. 2-5.Specifically, the manufacturing modules 32 of the manufacturing chain10, as shown in FIG. 1, may each include one or more of the modularmanufacturing stations 18, 20, 22, 24, 26, and 28, as dictated by themanufacturing process to be performed.

The station control systems 124 may include any commercially availablemicroprocessors that include means for controlling the operation of atleast one of the article transportation device 122 and the manufacturingequipment 120 of the respective manufacturing stations 18, 20, 22, 24,26, and 28. Generally, each station control system 124 may include aprocessor 222, a memory 224, and any other components for running anapplication. Various circuits may also be associated with the stationcontrol systems 124, such as utility supply circuitry, signalconditioning circuitry, and any other types of circuitry needed for theoperation of the respective manufacturing stations 18, 20, 22, 24, 26,and 28.

The station control systems 124 may each receive input from an operatorinterface 226, and may control and/or override the operation of thearticle transportation device 122 and/or manufacturing equipment 120 ofthe respective manufacturing stations 18, 20, 22, 24, 26, and 28 inresponse to the input. As should be appreciated, the operator interface226 may receive an operator input command that is indicative of adesired operation. Accordingly, the operator interface 226 may include atouch screen, keyboard, control panel, or any other device or mechanismcapable of facilitating communication between the operator and thestation control systems 124. It is also contemplated that the inputcould alternatively be a computer-generated command from an automatedsystem that assists the operator, or an autonomous system that operatesin place of the operator.

According to one embodiment, the memory 224 of each station controlsystem 124 may include a unique operation pattern corresponding to aspecific task stored thereon. For example, the unique operation patternmay include one or more operation signals to be transmitted to at leastone of the article transportation device 122 and the manufacturingequipment 120 via at least one communications conduit 228. Suchoperation signals may, for example, include the forward signal, thereverse signal, and the stop signal, as described above. In addition,the raise signal and the lower signal may be issued to an articletransportation device 122 that includes a vertical lift device, such asvertical lift devices 206 and 212. Further, operation signals, such as,for example, a begin operation signal and a stop operation signal thatmay, intuitively, start or stop operation of the manufacturing equipment120, may also be issued. It should be appreciated that a “uniqueoperation pattern,” as used herein, may generally refer to any sequenceor pattern of movements or operations that facilitate the performance ofa task, including such parameters as speed and direction of travel.

Each of the station control systems 124 may issue an operation signal,as describe above, in response to an operator input or, alternatively,automatically and according to a predetermined pattern, such ascorresponding to the unique operation pattern stored thereon. Accordingto one embodiment, the station control systems 124 may be incommunication with the position tracking devices 176, 178, and 180 viathe communications conduit 228, and may be configured to receive signalsindicative of detected carrier positions. The station control systems124 may also be configured to issue at least one of the operationsignals corresponding to the unique operation pattern, based, at leastin part, on one or more of the detected carrier positions.

A main control system 230 may be provided for coordinating operation ofthe station control systems 124 of each modular manufacturing station18, 20, 22, 24, 26, and 28. Alternatively, however, one of the stationcontrol systems 124 may be designated a master control system forcoordinating operation of the manufacturing chain 10. The main controlsystem 230 may be of standard design and may generally include aprocessor 232, such as, for example, a central processing unit, a memory234, and an input/output circuit, such as the communications conduit228. It should be appreciated that the communications conduit 228, asreferenced herein, may represent any form of wired and/or wirelesscommunications, and may generally represent the transmission of any ofthe operation signals and/or positions signals described above.According to one embodiment, one or more data communications may betransmitted via the utility transfer modules 40.

The processor 232 may control operation of the main control system 230by executing operating instructions, such as, for example, programmingcode stored in the memory 234, wherein operations may be initiatedinternally or externally to the main control system 230. As should beappreciated, a control scheme may be utilized that monitors outputs ofthe systems and/or components of each modular manufacturing station 18,20, 22, 24, 26, and 28, such as, for example, sensors, actuators, orcontrol units, via the communications conduit 228. Such information may,for example, be used to control inputs to the station control systems124 and/or other systems and components of the each of the modularmanufacturing stations 18, 20, 22, 24, 26, and 28.

According to one example, the memory 234 of the main control system 230may store a plurality of unique operation patterns thereon. The maincontrol system 230 may receive signals indicative of the first, second,and third detected carrier positions from each of the station controlsystems 124. In response, the main control system 230 may independentlytransmit operation signals, such as operation signals corresponding toone of the unique operation patterns, to each of the station controlsystems 124. The station control systems 124 may, in turn, transmit theoperation signals to the article transportation device 122 and/or themanufacturing equipment 120 at the respective stations 18, 20, 22, 24,26, and 28.

The main control system 230 may also index the carriers 164 of eachmodular manufacturing station 18, 20, 22, 24, 26, and 28 as each carrier164 traverses to a contiguous station 18, 20, 22, 24, 26, and 28.According to one embodiment, the main control system 230 maysimultaneously issue an index signal to the station control systems 124of each modular manufacturing station 18, 20, 22, 24, 26, and 28. Assuch, the processors 222 of each station control system 124 may beconfigured to await and/or anticipate the index signal from the maincontrol system 230 after the task to be performed at the respectivestation has been completed.

According to one example, indexing may include detecting a desiredposition of the carrier 164 within each station 18, 20, 22, 24, 26, and28, such as by using one or more of the position tracking devices 176,178, and 180. The main control system 230 may be configured to awaitsignals from each modular manufacturing station 18, 20, 22, 24, 26, and28 that are indicative of the desired position and then simultaneouslytransfer each carrier 164 to a contiguous station 18, 20, 22, 24, 26,and 28. Additional operation signals, therefore, may also be useful forindexing, such as, for example, the stop signal, a speed adjust signal,a transfer signal, or any other signal useful for detecting andtransferring the carriers 164.

By coordinating operation of the entire manufacturing chain 10, the maincontrol system 230 may receive a carrier position signal from onemodular manufacturing station and issue an operation signal to anothermanufacturing stations based, at least in part, on that carrier positionsignal. For example, it may be desirable to transfer the carrier 164 ofmodular manufacturing station 18 only when the carrier 164 of themodular manufacturing station 20 has reached a predetermined position,such as a position detected by one or more of the position trackingdevices 176, 178, and 180. It should be appreciated that the maincontrol system 230 may utilize position signals from all of the positiontracking devices 176, 178, and 180, at least in part, to coordinateoperation of the entire manufacturing chain 10.

The main control system 230 may also include an operator interface, suchas an interactive operator display 236, for continuously monitoringand/or controlling operation of each modular manufacturing station 18,20, 22, 24, 26, and 28 of the manufacturing chain 10. According to oneembodiment, the interactive operator display 236 may be used tocontinuously monitor a status of each article transportation device 122of the manufacturing chain 10. Further, the interactive operator display236 may be configured to display a real-time visual representation ofeach carrier 164 being transported through the manufacturing chain 10.The interactive operator display 236 may also be configured to receivean operator input command from an operator and transmit the operatorinput command to the article transportation device 122 or themanufacturing equipment 120 of at least one of the modular manufacturingstations 18, 20, 22, 24, 26, and 28.

It should be appreciated that numerous applications and configurationsof the control system 220 are contemplated. According to one embodiment,the main control system 230, station control systems 124, positiontracking devices 176, 178, and 180, article transportation devices 122and manufacturing equipment 120 may all be interconnected through alocal area network, as shown in FIG. 7. As such, the main control system230 may directly communicate with the systems and/or components of eachmodular manufacturing station 18, 20, 22, 24, 26, and 28, and,therefore, may not direct communications, including operation signals,through the station control systems 124. Similarly, position signals maybe communicated directly from the position tracking devices 176, 178,and 180 to the main control system 230.

An exemplary embodiment of a material handling system for use with themodular manufacturing chain 10, or modular manufacturing line, describedherein is shown generally at 250. The material handling system 250, onlya portion of which is shown, may include a composite beam 252 having anupper rail 254 and a lower track 256 connected through a plurality ofspaced apart transverse members 258. As shown later in greater detail,the lower track 256 may define two parallel channels 260. A trolley 262,several of which are shown, may include a lower set of wheels 264 thatmay be received within the two parallel channels 260 of the lower track256. The lower track 256, along which the trolley 262 is movable, maydefine a rail of any standard size, including, for example, a 3″, 4″, or6″ rail. An upper set of wheels 266 of the trolley 262 may be infrictional engagement with a drive tube 268 of a friction drive system270. The friction drive system 270, which may include a spinning tubefriction drive system as provided by OCS IntelliTrak of Cincinnati,Ohio, may be similar to an exemplary embodiment of the articletransportation device 122 described above, and may generally include aplurality of drive tubes 268 supported along the material handlingsystem 250 and positioned in series to define a path through the modularmanufacturing chain 10 (FIG. 1). Each of the plurality of drive tubes268 may be independently driven, or rotated, by one of a plurality ofmotors, such as electric drive motor 272. Therefore, depending on thenumber and length of independently driven drive tubes 268, the materialhandling system 250, or modular material handling system 250, may becustomized to independently control each article as it is transportedthrough the manufacturing chain 10.

As shown in the illustrated embodiment, a first trolley assembly 274 maybe configured to support a first load bar 276. Specifically, a first end278 of the first load bar 276 may be pivotably supported from a firsttrolley 280, while a second end 282 of the first load bar 276 may bepivotably supported from a second trolley 284. Similarly, second trolleyassembly 285 may be configured to support a second load bar 286. Morespecifically, a first end 288 of the second load bar 286 may bepiovtably supported from a third trolley 290, and a second end 292 ofthe second load bar 286 may be pivotably supported from a fourth trolley294. A carrier 296, which may include any devices capable of gripping anarticle to be conveyed along the modular material handling system 250,may have a first end 298 pivotably supported from the first load bar 276and a second end 300 pivotably supported from the second load bar 286.While a carrier, such as carrier 296, may be configured to support anarticle, load bars, such as first and second load bars 276 and 286, maybe configured to evenly distribute weight carried by the carrier 296among a plurality of trolleys 262. One skilled in the art shouldappreciate that a trolley assembly, such as first trolley assembly 274and second trolley assembly 285, may include any number of trolleys 262configured to directly or indirectly support a carrier, such as carrier296. Further, a load bar assembly, such as the illustrated load barassembly 302, may include any number of trolleys 262 or trolleyassemblies 274 and 285 supporting any number of load bars 276 and 286.Such arrangements may be customized based on the weight to be supportedby the carrier 296.

According to another arrangement, one or more of the trolleys 262 mayinclude a coupling mechanism for attaching the trolley 262 to anothertrolley 262. For example, the front of one trolley 262 may includecoupling means configured to attach to complementary coupling meansprovided on the back of another trolley 262. Alternatively, similarcoupling means may be provided to attach carriers, such as carrier 296,or load bars, such as load bars 276 or 286. Any such arrangements may besimilar, in purpose, to conventional couplings for attaching train carsto one another for pulling the train cars in a train. As such, one ormore trolleys 262, or carriers 296, may be transported along thematerial handling system 250 in a coupled configuration. Such a coupledconfiguration may, for example, be useful when transporting similararticles or when transporting different articles that may be latercombined into an assembly or a sub-assembly.

Although not depicted, it should be appreciated that a single trolley262, which may also be referenced as a trolley assembly, may beconfigured to directly support a carrier, such as carrier 296. As such,the friction drive system 270, and trolley 262, may be configured toensure that at least one of the wheels of the upper set of wheels 266continuously engages one of the drive tubes 268. Specifically, thewheels of the upper set of wheels 266 may bridge any gaps, such as gap304, between drive tubes 268 of the friction drive system 270. Fortrolley assemblies, such as trolley assemblies 274 and 285, which mayinclude one or more trolleys 262 connected through one or more loadbars, such as load bar 276, and/or carriers, such as carrier 296, it maybe important to ensure that at least one of the trolleys 262continuously engages one of the plurality of drive tubes 268.

The trolleys 262, described herein, may be of standard design, requiringa lower set of wheels 264, movable along the lower track 256, and anupper set of wheels 266 that are configured to frictionally engage theplurality of drive tubes 268. Such trolleys 262, according to oneembodiment, may be modified versions of conventional power and freeconveyor trolleys, or other trolleys known to those skilled in the art.To incorporate such standard components, a drive adapter may be providedthat attaches a standard trolley, having lower wheels that are movablewithin the lower track 256, to the upper set of wheels 266, describedherein. The upper wheels 266, as should be appreciated, are configuredto frictionally engage the plurality of drive tubes 268. Byincorporating such conventional components, such as by slightlymodifying standard trolleys as described herein, costs of implementingthe material handling system 250 may be reduced.

Turning now to FIGS. 9 a-9 c, cross-sectional views of alternativeembodiments of the composite beam 252 are shown. Specifically, thecomposite beam 252 of FIG. 9 a may include the upper rail 254 and lowertrack 256 connected through transverse members 258, as described abovewith reference to FIG. 8. As shown, each of the transverse members 258may have an inverted U-shaped cross-section defining a pair of free ends320. Each of the free ends 320 may support one of channels 260, whichmay be generally C-shaped channels, of the lower track 256. The channels260, according to one embodiment, may be welded, or otherwisepermanently affixed, to each of the plurality of transverse members 258.Although alternative attachment methods are contemplated, welding may bepreferred to provide increased structural strength of the composite beam252 and, further, may allow the transverse members 258 to be positionedat longer centers. The upper rail 254, as shown in FIG. 9 a, may,according to one embodiment, include a T-shaped cross-section defining acentral web 322 and a transverse flange 324. The central web 322, whichmay extend the length of the composite beam 252, may be received, andpermanently affixed, within a vertically aligned slot 326 of an upperportion 328 of each of the transverse members 258.

According to alternative embodiments, shown in FIGS. 9 b and 9 c, theupper rail 254 of the composite beam 252 may include a pair ofoppositely oriented structural members 330. Each of the structuralmembers 330 may include a vertically oriented web 332 that is secured toeach of the transverse members 258. Turning specifically to FIG. 9 b,each of the structural members 330 may be in the form of an angle ironhaving the vertically oriented web 332 and a horizontally orientedflange 334. The horizontally oriented flange 334, along with thetransverse flange 324 of the embodiment of FIG. 9 a, may be used tosecure a position of the composite beam 252 along the modularmanufacturing chain 10 (FIG. 1), as described below in greater detail.According to this embodiment, and alternative embodiments, the compositebeam 252 may also include a horizontally aligned support plate 336secured to each of the pair of free ends 320 of the transverse members258 and/or the channels 260 of the lower track 256.

The structural members 330, according to the embodiment of FIG. 9 c, mayinclude the vertically oriented webs 332, which may be attached to thetransverse members 258, and the horizontally oriented flanges 334, whichmay be used to attach the composite beam 252 to another structure. Inaddition, the structural members 330, as shown in FIG. 9 c, may includehorizontally oriented flanges 340 that may be fixedly attached to eachof the plurality of transverse members 258. Also shown in the embodimentof FIG. 9 c, the composite beam 252 may include a cable tray 342supported, or defined, by the composite beam 252. Specifically, thecable tray 342 may extend a length of the composite beam 252 and may bereceived, and secured, within openings 344 defined by the transversemembers 258. Alternatively, the cable tray 342 may not extend the lengthof the composite beam 252, but may be defined only by the openings 344of the transverse members 258. The cable tray 342 may be provided toaccommodate one or more cables or conduits provided along themanufacturing chain 10. For example, the cable tray 342 may accommodatethe utility transfer module 40, described above, which may be configuredto transfer a utility, such as, for example, electric power, fluid, ordata, through the modular manufacturing chain 10 of FIG. 1, or anothersimilar chain or line.

The one or more composite beams 252 of the material handling system 250may be provided in any desired length, and may include one or morestraight and/or curved sections. According to one embodiment, thecomposite beams 252, which may be made from iron, steel, aluminum,plastics, composites, and/or any other desired materials, may beprovided in specific lengths selected to ease assembly of the modularmanufacturing chain 10 of FIG. 1. Specifically, the composite beams 252may be pre-fabricated, or pre-constructed, prior to delivery to themanufacturing area 12 (FIG. 1). Further, each composite beam 252 may beshipped with a predetermined length of cable 356, an electric drivemotor 272, and a variable-frequency drive 358 for operating the electricdrive motor 272, each of which may be later repositioned. As shown inFIG. 10, each composite beam 252 may, according to the exemplaryembodiment, be provided in a length corresponding to a length of amanufacturing module 360. The manufacturing module 360, which may besimilar to the manufacturing module 32 described above, may include,according to one embodiment, a pair of end frames 362 connected throughone or more central beams that define a mid-frame 364. One or morecomposite beams 252 may be supported from the manufacturing module 32 byattaching, such as by bolting, a plurality of connecting clamps 366 tothe composite beam 252 and one or more of the mid-frame 364 and the endframes 362. Once at least one composite beam 252 is attached to themid-frame 364 and/or end frames 362, according to the exemplaryembodiment, the end frames 362 may be secured to floor supported beams(not shown). Specifically, end posts 368 may telescopically receive, ormay be otherwise attached to, corresponding floor mounted beams (notshown) to form the manufacturing module 360. Alternatively, rather thanend posts 368, the end frames 362 may include floor mounted supportstructures having an inverted “V-shape” oriented parallel to thecomposite beam 252.

According to yet alternative embodiments, the one or more compositebeams 252 may be supported directly by the building 14, such as throughcables suspended from a ceiling of the building 14. According to oneexample, the material handling system 250 may include a combination ofceiling or structure supported composite beams 252 and floor supportedcomposite beams 252. The ceiling supported composite beams 252, asshould be appreciated, may provide additional clearance foraccommodating equipment, such as manufacturing equipment. Yetalternatively, the one or more composite beams 252 may be inverted toprovide an on-floor conveyor, rather than the overhead conveyor that hasbeen described. As should be appreciated by those skilled in the art,such an on-floor conveyor may represent an inverted version of thematerial handling system 250 described herein, with articles andrespective carriers positioned, or supported, above the composite beams252.

As described above, a plurality of manufacturing modules 360 may bepositioned, such as in series, to define one or more paths through themodular manufacturing chain 10 of FIG. 1. The modular material handlingsystem 250, including one or more composite beams 252 and the frictiondrive system 270, described above, may be supported along the one ormore paths defined by the manufacturing modules 360. When supporting thematerial handling system 250, it is important to note that the compositebeams 252 and friction drive system 270 must be aligned to providecontinuous paths, as necessary. It should be appreciated that thefriction drive system 270, as referenced herein, may comprise aplurality of friction drive modules, each of which includes one of theplurality of drive tubes 268 and a corresponding electric drive motor272. Therefore, friction drive system 270, as used herein, may refergenerally to the drive system, or material handling system 250, usedthroughout the entire modular manufacturing chain 10 (FIG. 1), or to aspecific one or more of the modules, or segments, of the friction drivesystem 270.

According to one implementation of the material handling system 250,shown in FIG. 11 a, one or more manufacturing modules 360 of amanufacturing line, such as the manufacturing chain 10 of FIG. 1, mayinclude a dual track, or multiple track, assembly. Specifically, asshown in the simplified plan view of FIG. 11 a, the material handlingsystem 250 may include a first track assembly 380 configured totransport a forward trolley assembly 382, including one or more trolleys262, along a first path 384, and a second track assembly 386 configuredto transport a trailing trolley assembly 388, including one or moretrolleys 262, along a second path 390. Each track assembly 380 and 386may include one or more composite beams 252 and a friction drive system270, as described above. The composite beams 252 of the first and secondtrack assemblies 380 and 386 may be positioned, and/or secured, adjacentone another, without substantial modification, and, as such, may definepaths 384 and 390 through one or more modules 360 that are substantiallyparallel. Together, the parallel paths 384 and 390 may define atransportation path 392 along which the forward trolley assembly 382 andthe trailing trolley assembly 388 are spaced.

A carrier 394, configured to support an article, may have a first end396 pivotably supported by the forward trolley assembly 382 and a secondend 398 pivotably supported by the trailing trolley assembly 388.According to a specific arrangement, shown in FIG. 11 b, the first end396 of the carrier 394 may be supported by the forward trolley assembly382 through a first load bar assembly 410, while the second end 398 ofthe carrier 394 may be supported by the trailing trolley assembly 388through a second load bar assembly 412. Such a multiple track assembly,including two or more track assemblies, may be used to support articlesof a substantial weight, such as, according to some embodiments, up toabout 80,000 pounds. According to such arrangements, it may be desirablefor the modular material handling system 250 to include at least thefirst track assembly 380 and the second track assembly 386 throughoutthe entire manufacturing chain 10, or line. However, it may be desirableto provide the multiple track assembly in only one or more modules ofthe manufacturing chain 10, as will be described below. It should beappreciated that, in such multiple track arrangements, it may bedesirable to utilize the friction drive system 270 described herein,which inherently allows slippage, to successfully navigate any curvesalong the transportation path 392. Specifically, for example, one of theforward trolley assembly 382 and the trailing trolley assembly 388 maytravel a greater distance than the other around such curves.

According to another implementation, the manufacturing chain 10 mayinclude one or more buffers, such as a buffer 430, as shown in FIG. 12.Specifically, the buffer 430, which may also be referred to as asequencing buffer, may include a first track assembly 432 sized toreceive at least two trolley assemblies 434, and a second track assembly436 that is also sized to receive and support at least two trolleyassemblies 434. According to some implementations, it may be desirableto provide a third track assembly 438, similar to the first trackassembly 432 and the second track assembly 436, or any number ofadditional track assemblies. Each of the first, second, and third trackassemblies 432, 436, and 438 may be vertically spaced, as shown, or maybe otherwise positioned, as described below.

Each of the track assemblies 432, 436, and 438 may include any number ofmanufacturing modules 360 positioned such that the material handlingsystem 250 of each track assembly 432, 436, and 438, including one ormore composite beams 252 and a friction drive system 270, defines acontinuous path along the respective track assembly 432, 436, or 438.According to one embodiment, each module 360 may include one drive tube268 and a corresponding electric drive motor 272 for transporting thetrolley assemblies 434 along the first, second, and third trackassemblies 432, 436, and 438 in a forward or reverse direction. Asshown, each trolley assembly 434 may include a pair of trolleys 262configured to support an article 440 using a carrier 442. It should beappreciated, however, that any number of trolleys 262 may be configuredto directly or indirectly support the carrier 442.

The buffer 430, illustrated as a stackable buffer, may also include afirst movable track assembly 444 that may include the material handlingsystem 250 described above. The first movable track assembly 444 may besupported by a manufacturing module 360 and may be movable between aplurality of positions. For example, the first movable track assembly444 may have a first position that defines a continuous path along thefirst movable track assembly 444 and the first track assembly 432. A“continuous path,” as used herein, may reference any path along which atrolley 262 may be continuously transported. The first movable trackassembly 444 may also include a second position (shown) defining acontinuous path along the first movable track assembly 444 and thesecond track assembly 436. Further, for embodiments having a third trackassembly 438, the first movable track assembly 444 may have a thirdposition defining a third continuous path along the first movable trackassembly 444 and the third track assembly 438.

A first programmable hoist 446, or other similar transfer device, may beconfigured to move the first movable track assembly 444 between thefirst, second, and third positions described above. The firstprogrammable hoist 446 may be of conventional design and, further, maybe integrated with the control system 220, described above. The firstmovable track assembly 444 may be positioned at a first end 448 of thebuffer 430, or at any other desired position along the buffer 430.Further, the buffer 430, according to the exemplary embodiment, mayinclude a second movable track assembly 450 positioned at a second end452 of the buffer 430. The second movable track assembly 450, similar tothe first movable track assembly 444, may be movable using a secondprogrammable hoist 454, or other similar transfer device. Specifically,the second movable track assembly 450 may be movable between a firstposition (shown) defining a continuous path along the second movabletrack assembly 450 and the first track assembly 432, a second positiondefining a continuous path along the second movable track assembly 450and the second track assembly 436, and a third position defining acontinuous path along the second movable track assembly 450 and thethird track assembly 438.

It should be appreciated that the track assemblies 432, 436, and 438 ofthe buffer 430 may, according to one alternative embodiment, behorizontally spaced, rather than vertically spaced. According to suchimplementations, the buffer 430 may utilize one or more lateralshuttles, described below, rather than programmable hoists 446 and 454,to move the movable track assemblies 444 and 450 into alignment with oneof the first, second, and third track assemblies 432, 436, and 438. Suchdesign choices, for example, may be based on spatial constraints of themanufacturing area 12 (FIG. 1) and/or specific needs of themanufacturing processes that are supported. As such, the buffer 430 mayinclude any number of stationary track assemblies, such as trackassemblies 432, 436, and 438, having any desired capacity, positionedand/or stacked according to a customized configuration. Further, thebuffer 430 may include any number of movable track assemblies, such asmovable track assemblies 444 ad 450, positioned at any useful positionsthroughout the buffer 430. Such a customized buffer 430 may be used totransport, store, sequence, and/or re-sequence carriers 442 and/orarticles 440 supported thereon, as described below in greater detail.

During an exemplary operation, one or more of the trolley assemblies 434may be distributed among the first track assembly 432 and the secondtrack assembly 436 of the buffer 430 such that a first trolley assembly456 is blocked from an exit position 458. The exit position 458 mayrepresent a position within the buffer 430 from which a trolley assembly434 may be removed from the buffer 430 without having to move anothertrolley assembly 434. For example, the exit position 458 may include aposition that accommodates a continuous path onto a main path of amanufacturing line. To move the first trolley assembly 456 to the exitposition 458, the plurality of trolley assemblies 434 may beredistributed among the first track assembly 432 and the second trackassembly 436. For example, a second trolley assembly 460, currently atthe exit position 458 and blocking the first trolley assembly 456 fromthe exit position 458, may be moved along the first track assembly 432using the friction drive system 270 and onto the first movable trackassembly 444. The first movable track assembly 444 may then be raised,using the first programmable hoist 446, from the first position to thesecond position (shown). At the second position of the first movabletrack assembly 444, the second trolley assembly 460 may be moved fromthe first movable track assembly 444 and onto the second track assembly436, using the friction drive system 270. As a result, the first trolleyassembly 456 may be moved along the first track assembly 432 and intothe exit position 458.

It should be appreciated that, in the exemplary operation describedabove, the second track assembly 436 was not at its illustrated capacityof three trolley assemblies 434 and, therefore, the second trolleyassembly 460 could more easily be moved onto the second track assembly436. However, if the second track assembly 436 were supporting a maximumnumber of trolley assemblies 434, it may be necessary to move one of thetrolley assemblies 434 from the second track assembly 436 to the firsttrack assembly 432. For example, the second movable track assembly 450may be moved from the first position (shown) to the second position,described above. Next, a third trolley assembly 462 may be moved alongthe second track assembly 436 and onto the second movable track assembly450. The second movable track assembly 450 may then be lowered, such asby using the second programmable hoist 454, from the second position tothe first position, such that the third trolley assembly 462 may bemoved from the second movable track assembly 450 and onto the firsttrack assembly 432.

It should also be appreciated that, if both the first track assembly 432and the second track assembly 436 are at maximum capacity, trolleyassemblies 434 may be simultaneously moved, or shifted, through thebuffer 430. For example, the friction drive system 270 of the firsttrack assembly 432 may transport the trolley assemblies 434 in a firstdirection, while the friction drive system 270 of the second trackassembly 436 may transport the trolley assemblies 434 in a seconddirection that is opposite the first direction. Specifically, thetrolley assemblies 434 may be shifted in clockwise direction or acounterclockwise direction through the buffer 430 to move a desiredtrolley assembly 434 to the exit position 458. As should be appreciated,to provide such re-sequencing when the buffer 430 is at, or near,maximum capacity, it may be preferable to utilize at least two or moremovable track assemblies, such as movable track assemblies 444 and 450.Further, it should be appreciated that the friction drive system 270 or,more specifically, friction drive modules corresponding to each of thetrack assemblies 432, 436, and 438 and movable track assemblies 444 and450 may provide independent movement and control of each of the trolleyassemblies 434 positioned therein.

Turning now to FIG. 13, a high level view of a first line 480 is shown.The first line 480 may be similar to, or may include, the modularmanufacturing chain 10 described above with reference to FIG. 1.Specifically, the first line 480 may include a plurality of stationarymodules, such as modules 32 (FIGS. 1-5) or modules 360 (FIG. 10),positioned in series, or in parallel, and defining at least one path481, which may include a main path, through the first line 480. Thefirst line 480 may utilize the material handling system 250, asdescribed above, including one or more composite beams 252 supportingthe friction drive system 270. Generally, according to one example, thefirst line 480 may include first operations 482 and a logistics area484, both of which may receive articles, such as parts, from suppliers486. From first operations 482, parts, or other articles, may betransported to fabrications 488, using the material handling system 250,by supporting the parts using carriers, as described above. From bothlogistics 484 and fabrications 488, articles may be transported to paintshop 490 or sub-assembly 492.

As shown, the first line 480 may include a plurality of buffers 494,which may be similar to the buffer 430 described above with reference toFIG. 12. The buffers 494 may be positioned anywhere along the first line480, such that carriers, and articles supported thereon, may be routedoff the one or more main paths 481 and into the buffers 494. Asdescribed above, the buffers 494 may be used to store and/or re-sequencecarriers and/or articles. A plurality of spurs 495 may also be providedthroughout the first line 480 for storing and/or re-sequencing carriers,in a manner described in greater detail below. Further, the articles mayremain on the same carriers continuously throughout the first line 480,which may span one or more buildings or manufacturing areas. Forexample, parts and/or sub-assemblies may be stored in one of the buffers494, or other storage areas, until they are transported, such as byusing a trolley assembly 496, similar to those described above, to anassembly line 498 or to one or more stations 500 along the assembly line498. The articles and/or carriers may be tracked, such as by usingbarcodes, sensors, and the control system 220 described above, to accessand route the parts to the assembly line 498 and/or stations 500precisely when they are needed.

A mobile module 502, having ground-engaging elements 504, may be used totransport an article, such as a part, sub-assembly, or assembly, fromthe first line 480 to a second line 520, as shown in FIG. 14.Specifically, the mobile module 502 may be movable between, at least, afirst position 506, as shown in FIG. 13, to a second position 522, asshown in FIG. 14. The mobile module 502 may include one or more modules,such as modules 32 (FIGS. 1-5) or 360 (FIG. 10) supported by a frame,such as an enclosed portion of a vehicle or other mobile device. Forexample, the mobile module 502 may represent a mobile version of one ofthe stationary modules 32 or 360 described above, and may be movableusing any known transportation means. The mobile module 502 may alsoinclude a material handling system 250, including one or more compositebeams 252 supporting a friction drive system 270, as described above. Itshould be appreciated that in both the first position 506 and the secondposition 522, the material handling system 250 of the mobile module 502may be aligned with a portion of the material handling system 250 of therespective line 480 or 520, such that a trolley assembly, such astrolley assembly 492, may be continuously transported along therespective material handling systems 250. According to anotherembodiment, the material handling system 250 may provide a continuouspath between adjacent buildings. Further, an enclosure may be providedto protect the material handling system 250 and any articles transportedthereon from the weather, and other adverse conditions, to which theymay be exposed between buildings. As should also be appreciated,transporting an article on its respective carrier may allow the carrierand, thus, article to be tracked while it is transported between remotebuildings, locations, etc., as described herein.

Referring also to FIGS. 1-13, the second line 520 of FIG. 14 may alsoinclude a plurality of stationary modules 32 or 360 positioned in seriesand defining at least one path through the second line 520. The secondline 520 may utilize the material handling system 250, as describedabove, including one or more composite beams 252 supporting a frictiondrive system 270. Generally, the second line 520 may include one or moretrack switches, which may each be positioned between two of theplurality of drive tubes 268. According to one example, a first trackswitch 524, which may include a movable track assembly 525, may bemovable between a first position defining a first path 526, and a secondposition defining a second path 528. As shown, the second path 528 maybe positioned at an angle that is greater than zero with respect to thefirst path 526. By moving the first track switch 524 from the firstposition to the second position, a carrier, such as carrier 530, may betransported through the first track switch 524 and onto a spur 532 (asshown). It should be appreciated that the spur 532, and additionalspurs, may be positioned along the second line 520 and used fortemporary storage and/or carrier re-sequencing. For example, the carrier530 may be routed onto the spur 532, the first track switch 524 may bemoved back to the first position, and one or more additional carriers,such as carrier 534, may proceed along the first path 526 in advance ofcarrier 530.

The spur 532 may also provide a means for turning carriers around. Forexample, the carrier 530 may be transported, such as in a forwarddirection, along the second path 528 and past a second track switch 534.The second track switch 534 may also include a movable track assembly536 that is movable between a first position defining the second path528 and a second position defining a third path 538. After the carrier532 is moved along the second path 528 and past the second track switch534, the second track switch 534 may be moved to the second position,such that the carrier 532 may be moved, in a reverse direction, alongthe third path 538. Further, a third track switch 540, also including amovable track assembly 542, may be movable between a first positiondefining the first path 526 and a second position defining the thirdpath 538. Thus, when the third track assembly 540 is in the secondposition, the carrier 532 may be transported from the spur 532, in thereverse direction, and back along the first path 526, with the articlesupported by carrier 530 having an orientation that is 180° opposite itsprevious orientation.

Additional means for turning around a carrier, such as the carrier 530,may include movement of a track assembly using a known gantry track, orcrane. Specifically, for example, a gantry track, which may provide afixed structure about which the track assembly may be pivoted, may beused alone or in combination with one or more track switches toreposition a track assembly with respect to a main path, such as thefirst path 526. Due to the modularity of the material handling system250, gantry tracks, which may be traveling, portable, or fixed, may alsobe used to move a carrier, such as carrier 530, between one or morealternative paths, thus operating as a shuttle. Such a shuttle, asshould be appreciated, may be used to align a movable track assemblywith one of a plurality of track assemblies, thus providing alternativepaths for the carrier 530.

Track switches, as described above, may be incorporated along the secondline 520 for additional purposes. For example, a track switch, such as afourth track switch 544 having a movable track assembly 546, may be usedto transition a carrier, such as carrier 548, onto a dual trackassembly, which may be similar to the dual track assembly describedabove with reference to FIGS. 11 a and 11 b. For example, a firsttrolley assembly 550, supporting the carrier 548 may be transportedthrough the fourth track switch 544 and along the first path 526, whilethe fourth track switch 544 is in a first position. The fourth trackswitch 544 may then be moved into a second position, which defines afourth path 552. As such, a second trolley assembly 554 may betransported along the fourth path 552, which may be substantiallyparallel to the first path 526. It should be appreciated that movementof the first trolley assembly 550 and the second trolley assembly 554may be controlled to position the carrier 548, and the one or morearticles supported thereon, at any desired angle with respect to thedirection of travel. As should be appreciated, there may be one or moremodules 360 through which it may be desirable to transport articles atalternative angles, such as, for example, paint or wash modules.Further, it should be appreciated that such diagonal orientation of thecarrier 548 may be useful when storing a plurality of carriers, similarto carrier 548, along a spur, such as spur 532, or within a buffer, suchas buffer 430. Specifically, a substantial amount of space may be savedby accumulating carriers, such as carrier 548, at diagonal orientationsrelative to the direction of travel by providing the dual paths 526 and552 and track switch 544, as described above.

After transporting the carrier 548 through one or more modules 360 at analternative angle with respect to the direction of travel, a fifth trackswitch 556 may be positioned along the second line 520 to return thesecond trolley assembly 554 to the first path 526. Track switches, suchas a sixth track switch 558, may also be used to route carriers throughone or more alternative paths through the second line 520. For example,the sixth track switch 558 may be used to route carriers along either ofthe first path 526 and a fifth path 560. As shown, the first path 526may include one or more curves, such as curves 562 and 564. To navigatearound such curves, according to one embodiment, a first trolleyassembly 564 of a carrier 566 may be disengaged from a first drive tube568, while a second trolley assembly 570 of the carrier 566 may beengaged with the first drive tube 568. As such, the first trolleyassembly 564 may be pushed around the curve 562 using the second trolleyassembly 570. As the carrier 566 travels through the curve 562, thefirst trolley assembly 564 may engage a second drive tube 572. Thesecond trolley assembly 570 may eventually disengage from the firstdrive tube 568, thus allowing the first trolley assembly 564 to pull thesecond trolley assembly 570 around the curve 562. Specifically, forexample, such curves 562 may be navigated by positioning drive tubes 568and 572, such as linear drive tubes, such that at least one trolleyassembly 564 or 570 continuously engages one of the drive tubes 568 and572.

If a carrier, such as a carrier 574, is transported along the fifth path560, a first trolley assembly 576 and a second trolley assembly 578 mayultimately transition the carrier 574 around a curve 580. When thecarrier 574 is positioned along the curve 580, and the first trolleyassembly 576 and the second trolley assembly 578 are stopped, ends 582and 584 of the carrier 574 may extend beyond a perimeter 586 defined bythe curve 580. When positioned as shown, the carrier 574 may be removedfrom the fifth path 560 using a programmable hoist 588. The programmablehoist 588, which may be of conventional design, may include one or moretrack assemblies 590 along which the programmable hoist 588 may bemovable. Specifically, the programmable hoist 588 may move the carrier574, and the article supported thereon, through one or more modules 360,lowering and raising the carrier 574, as necessary. The programmablehoist 588, according to one embodiment, may be supported on its owncarrier, which may be supported by one or more trolleys that are movablealong track assemblies 590, as described herein. More specifically, thecarrier and trolleys supporting the programmable hoist 588 may operateas a bridge crane moving along the track assemblies 590, which may serveas runways for the bridge crane. Further, a track assembly, such astrack assemblies 590 including one or more composite beams 252, may beused as the bridge between the runways. Yet further, one of the trackassemblies described herein may be configured as a gantry crane, inwhich one end of the track assembly is pivotable about the other.

After the carrier 574 is transported through one or more modules 360using the track assemblies 590 and programmable hoist 588, the carrier574, and article supported thereon, may again be supported on one ormore trolley assemblies. Specifically, the carrier 574 may be supportedby a first trolley assembly 592 and a second trolley assembly 594, whenthe first trolley assembly 592 and the second trolley assembly 594 arepositioned around a curve 596 of a sixth path 598. The sixth path 598may be positioned to route the carrier back to the first path 526, asshown. It should be appreciated that the article may remain on the samecarrier 574 throughout the transition of the carrier 574 to and from theprogrammable hoist 588. It should also be appreciated that thistransition, and others described herein, are intended as examples onlyand, therefore, should not limit the second line 520, or materialhandling system 250 thereof, in any way.

An additional spur 600 may be positioned along the second line 520 tostore and/or re-sequence carriers, as described above. Specifically, aseventh track switch 602 and an eighth track switch 604 may be movableto route one or more carriers into and out of the spur 600. As shown,one or more modules 360 positioned along the spur 600, and/or othermodules, may include a zigzag support frame 606. Specifically, as analterative to the end frames 362 and mid-frame 364 of FIG. 10, one ormore modules 360 may include beams 608, or headers, that are oriented atan angle, or cross-oriented, with respect to a travel direction throughthe module 360. The beams 608 may be attached to end posts 368, asshown, and may support one or more composite beams 252, as describedabove. Although the modules 360 are shown as including twocross-oriented beams 608, it should be appreciated that each module 360may include only one beam having an angled orientation with respect tothe direction of travel. For example, consecutive modules 360 mayinclude headers, or beams, that are oriented at alternative angles, butthat define a continuous zigzag support structure through the modules360. Such arrangements, as should be appreciated, may require fewerbeams and, therefore, less material for construction of modules 360.Further, in addition to reduced material cost, such arrangements,utilizing fewer beams, may require less time for assembly of the modules360.

A shuttle, such as a lateral shuttle 610, may be positioned at an end612 of the second line 520, as shown. According to one embodiment, thelateral shuttle 610 may include one or more trolley assemblies, such asany of the trolley assemblies described herein, that are movable alongone or more track assemblies, also described herein. The trolleyassemblies may support an additional track assembly 614, orientedperpendicular to the track assemblies along which the trolley assembliesare moved, which is movable to define alternative paths. According tothe exemplary embodiment, for example, the track assembly 614 mayinclude a position defining a seventh path 616, a position defining acontinuous path along the first path 526 (shown), and a positiondefining an eighth path 618. However, as should be appreciated, such ashuttle 610 may be movable to define any number of alternative paths forone or more carriers, such as a carrier 620, positioned thereon.

According to the illustrated embodiment, the track assembly 614 may bemoved, such as by using the shuttle 610, to align with the eighth path618 of the second line 520. When the track assembly 614 is positioned todefine a continuous path, the carrier 620, and article supportedthereon, may be moved onto the eighth path 618. As shown, the eighthpath 618 may also include a curve 622, from which the article may beremoved from the second line 520. According to one example, the articlemay be removed from the second line 520 only for delivery to a customer.Alternatively, however, the article may be transported to a customerusing the mobile module 502, as described herein. If the article isremoved from the carrier 620, the empty carrier 620, according to oneembodiment, may be returned to the track assembly 614. The shuttle 610may then be used to move the track assembly 614 to align with theseventh path 616, which may route the empty carrier 620 to one or moredesired locations, such as, for example, a storage buffer 624, which maybe similar to the buffer 430 of FIG. 12. According to one example, theseventh path 616 may include one or more composite beams 252, describedherein, which may be supported from one or more modules 360.Specifically, one or more modules 360 may support one or more compositebeams 252 defining a first path through the modules 360, and one or morecomposite beams 252 defining an additional path adjacent the modules 360for empty carrier returns.

It should be appreciated that alternative arrangements may be used forcarrier, or empty carrier, returns. For example, a buffer, such as thebuffer 430 described above, may be used to define a first, main, pathand a second, return, path. One or more movable track assemblies, suchas movable track assemblies 444 and 450 of FIG. 12, may be used totransition carriers from the main path to the return path, in a mannersimilar to that described above. Such transitions, also referred to asan over-under conveyance, may be incorporated, as needed, into the firstline 480 and/or the second line 520. For example, one of the stationarytrack assemblies of the buffer 430 of FIG. 12 may be positioned along amain path, such as the main path 481 of the first line 480 or the firstpath 526 of the second line 520. Alternatively, one or more carriers maybe routed off the main path 481 or first path 526 and into the buffer430, such as by actuating one or more track switches, as describedherein.

The carrier 620 may, alternatively, be routed through the shuttle 610along the first path 526 and, for example, onto a mobile module, such asthe mobile module 502. In a third position 626 (shown) of the mobilemodule 502, the material handling system, such as material handlingsystem 250 described herein, of the mobile module 502 may be alignedwith the material handling system 250 of the second line 520 such thatthe carrier 620 may be continuously transported from the first path 526and onto the mobile module 502. From there, the mobile module 502 mayreturn the carrier 620, and article supported thereon, to the first line480. It should be appreciated that the first line 480 and the secondline 520 may represent one or more manufacturing lines positioned inadjacent buildings or, alternatively, at remote locations.

The modular material handling system 250, as described herein withreference to the preceding figures, may be used as a common materialhandling system throughout an entire manufacturing, or production,process. For example, the material handling system 250 may be usedthroughout the first line 480 (FIG. 13), the second line 520 (FIG. 14),and any number of mobile modules 502 that may be configured to transportarticles between the first line 480 and the second line 520.Specifically, the same material handling system 250 may be used to routean article through all of the implemented manufacturing processes,including, for example, first operations 482, logistics 484,fabrications 488, paint 490, sub-assembly 492, and assembly 498 of thefirst line 480. Although specific examples are provided, it should beappreciated that the modular material handling system 250, as describedherein, may be used to support any number and/or combination ofmanufacturing processes.

Further, the configuration of the material handling system 250,including composite beams 252 and friction drive system 270, as shown inFIG. 8, may provide a modular material handling system that may berelatively quickly and easily assembled and/or modified. Specifically,as described with reference to FIG. 10, each of a plurality ofmanufacturing modules 360 may be assembled by connecting a mid-frame 364to a pair of end frames 362, and supporting a pre-constructed compositebeam 252 from the interconnected frames using one or more connectingclamps 366. The friction drive system 270, and other systems orcontrols, may be supported from the module 360 and, further, may beconnected to any necessary utilities via a utility transfer module 40,as described above. Further, an Andon system, as is known in the art,may be integrated with the any of manufacturing lines 10, 480, and 520and, further, with the control system 220. For example, a visualindication of a problem identified, either manually or automatically, ata specific module 32 or 360 may be provided. It should be appreciatedthat the systems, controls, and equipment used herein may all beprovided with plug and play functionality to further ease assemblyand/or modification of the manufacturing modules 360.

The composite beams 252, embodiments of which are illustrated in FIGS. 9a-9 c, and friction drive system 270 of material handling system 250 maysupport a wide range of weights. Specifically, for example, thecomposite beams 252 may support any of a variety of articles, rangingfrom small parts to large sub-assemblies, using one or more trolleys 262of the friction drive system 270, which may be configured to directly orindirectly support articles. By supporting such a wide range of weights,the material handling system 250 may be used in a variety of industries,and throughout processes that normally integrate multiple materialhandling systems or devices, including forklifts, to transport bothsmall and large articles. According to one example, the materialhandling system 250, as described herein, may be used to transport bothlarge sub-assemblies and small parts along the main path 481 of thefirst line 480 (FIG. 13). Specifically, for example, a largesub-assembly may be transported from sub-assembly 492 to the assemblyline 498 along path 481, while a plurality of small parts may betransported from one of the buffers 494 to stations 500 along the samepath 481. Alternatively, either or both of the first line 480 and thesecond line 520 may integrate a material handling system 250 sized tosupport lighter weights with a material handling system 250 sized tosupport heavier weights. Further, such embodiments may incorporate weighstations along the material handling systems 250 to ensure that trolleys262 are not routed along paths incapable of providing sufficientsupport. Alternatively, a control system, such as the control system 220described above, may track the weight of each article transported alongthe one or more integrated material handling systems 250 and routerespective trolleys 262 accordingly.

To increase the versatility of the material handling system 250, avariety of devices and/or features, including, but not limited to trackswitches, spurs, buffers, programmable hoists, shuttles, and gantrytracks, examples of which are provided herein, may be integrated withthe material handling system 250, as described above. As should beappreciated, these devices and/or features may be utilized by thematerial handling system 250 to provide numerous and useful transitionsof articles throughout a manufacturing, or production, process. Further,the material handling system 250, and devices or features incorporatedtherein, may be integrated with a control system, such as the controlsystem 220, to coordinate the processes for and movements of eacharticle transported along the material handling system 250.Specifically, by tracking and controlling each article, flow throughoutthe manufacturing process can be better organized, thus reducing wasteand improving efficiency.

INDUSTRIAL APPLICABILITY

The manufacturing chain 10 of the present disclosure may provide aportable and flexible manufacturing chain that supports an improvedmanufacturing process. Specifically, the manufacturing chain 10 includesmanufacturing modules 32 that may be relatively quickly and easilytransported and deployed. In addition, modular manufacturing stations18, 20, 22, 24, 26, and 28 may be readily added to and/or removed fromthe modules 32 of the manufacturing chain 10. Further, the articletransportation system 30, and method of operation thereof, may allowindependent process control at each modular manufacturing station 18,20, 22, 24, 26, and 28 and, therefore, may provide improved efficiencywith respect to the manufacturing process. Although a paint process isdescribed, it should be appreciated that the manufacturing chain 10, asdescribed herein, may be used to perform any of a variety ofmanufacturing processes.

Referring generally to FIGS. 1-14, the manufacturing chain 10, such as,for example, a paint line, may be deployed by erecting a plurality ofmanufacturing modules 32, as needed. Specifically, a plurality ofsupport beams 82, 84, 86, 88, 98, 100, 102, and 104 may be secured tothe planar floor 16 of a manufacturing area 12 and may be interconnectedto provide a framework or skeleton 80. One or more of the support beamssupport beams 82, 84, 86, 88, 98, 100, 102, and 104 may be capable ofexpansion and/or contraction to further ease the transport and/ordeployment of each manufacturing module 32. The skeleton 80 may providestructural support for one or more modular manufacturing stations, suchas, for example, the first modular manufacturing station 118 and thesecond modular manufacturing station 160 and/or the modularmanufacturing stations 18, 20, 22, 24, 26, and 28. Further, the skeletonmay include pre-constructed utilities, namely a utility transfer module40, supported by one or more of the support beams 82, 84, 86, 88, 98,100, 102, and 104.

Each modular manufacturing station, such as stations 118 and 160, mayinclude at least one piece of manufacturing equipment 120, an articletransportation device 122 representing a portion of the articletransportation system 30 corresponding to the respective station, and astation control system 124. It should be appreciated that themanufacturing equipment 120 may be positioned above the planar floor 16and may be portable to facilitate movement of the equipment 120 from onelocation, such as a storage location, and into an operable positionrelative to the station. The manufacturing equipment 120, as well as thearticle transportation device 122, the station control system 124, andvarious other systems and/or components of each station 118 and 160 mayreceive one or more utilities from the utility transfer module 40.

It should be appreciated that modifying the manufacturing chain 10, suchas adding or removing a modular manufacturing station may also beaccomplished with relative ease. Specifically, a modular manufacturingstation, similar to manufacturing stations 116 and 180, may be added tothe manufacturing chain 10 by interconnecting a plurality of beams 82,84, 86, 88, 98, 100, 102, and 104 to form a skeleton 80. The skeleton 80may be connected to or, alternatively, positioned adjacent a contiguousmanufacturing module 32. A utility transfer module 40, which may besupported by one of the beams 82, 84, 86, 88, 98, 100, 102, and 104, maybe connected to a utility transfer module 40 of the contiguousmanufacturing module 32 to provide utilities to the added manufacturingstation.

One or more of an article transportation device 122, a piece ofmanufacturing equipment 120, and a station control system 124 may besupported by the skeleton 80, or otherwise positioned within an operabledistance of the added manufacturing station. In addition, one or more ofthe article transportation device 122, the manufacturing equipment 120,and the station control system 124 may be connected to the utilitytransfer module 40 to receive one or more utilities therefrom, such asusing quick connect coupling members, as described above.

Operation of the manufacturing chain 10 may be controlled and/orcoordinated using the control system 220. Specifically, one or more ofthe main control system 230 and the station control systems 124 may beconfigured to advance at least one carrier 164 from a beginning of themanufacturing chain 10 to an end of the manufacturing chain 10, such asin the forward transport direction “F.” This advancement, according to aspecific example, may include independently moving a carrier 164 of thefirst modular manufacturing station 118 according to a first uniqueoperation pattern and a carrier 164 of the second modular manufacturingstation 160 according to a second unique operation pattern. According toone embodiment, the first unique operation pattern may include theforward transport direction “F” and the reverse transport direction “R.”The second unique operation pattern may, for example, include moving thecarrier 164 in the vertical direction relative to the transportationpath 166, such as by raising and/or lowering the carrier 164.

The memory 234 of the main control system 230 may store the first andsecond unique operation patterns for controlling operation of the firstand second modular manufacturing stations 118 and 160, respectively,thereon. The first position tracking devices 176 of each modularmanufacturing station 118 and 160 may detect a first position of eachcarrier 164 as it is transported through the respective one of themanufacturing stations 118 and 160, and transmit first position signalsto the main control system 230. It should be appreciated that any of theoperation signals, including position signals, may be transmittedthrough the station control systems 124.

The processor 232 of the main control system 230 may be configured toindependently transmit an operation signal corresponding to each of thefirst and second unique operation patterns to the respective one of themanufacturing stations 118 and 160 based, at least in part, on thedetected first positions. For example, the processor 232 mayindependently transmit one or more operation signals, such as, forexample, the forward signal, to each article transportation device 122upon detecting that each carrier 164 is entering the respective one ofthe modular manufacturing stations 118 and 160. Similarly, the processor232 may be configured to independently transmit one or more operationsignals to the manufacturing equipment 120 based, at least in part, onthe detected first positions.

In addition, the second position tracking devices 178 and the thirdposition tracking devices 180 of the manufacturing stations 118 and 160may detect second and third positions, respectively, and transmit secondand third position signals to the main control system 230, such asthrough the station control systems 124. The processor 232 may also beconfigured to independently transmit an operation signal correspondingto each of the first and second unique operation patterns to therespective one of the manufacturing stations 118 and 160 based, at leastin part, on one of the detected second and third positions. Similarly,the processor 232 may be configured to independently transmit one ormore operation signals to the manufacturing equipment 120 based, atleast in part, on one of the detected second and third positions.

For example, the processor 232 may be configured to transmit the reversesignal to the article transportation device 122 of the first modularmanufacturing station 118 upon detecting that the carrier 164 hasreached a predetermined position relative to the manufacturing equipment120. Similarly, the processor 232 may be configured to transmit thelower signal to the article transportation device 122, or secondvertical lift device 212, of the second modular manufacturing station160 upon detecting that the carrier 164 has reached a predeterminedposition relative to the manufacturing equipment 120. Determining thatthe carrier 164 has reached the predetermined position, in eitherexample, may be based, at least in part, on one of the second and thirdposition signals.

In addition, the processor 232 of the main control system 230 may beconfigured to index the carriers 164 of each modular manufacturingstation 118 and 160 as each carrier 164 traverses to a contiguousmanufacturing station. Indexing may, for example, include detecting oneof the second and third positions, as described above, of each carrier164 and simultaneously transferring each carrier 164 to a contiguousmanufacturing station.

It should be appreciated that manufacturing chain 10, including aplurality of modular manufacturing stations 18, 20, 22, 24, 26, and 28,as described herein, may be deployed and/or modified with relative ease.Each modular manufacturing station 18, 20, 22, 24, 26, and 28, asfurther exemplified by first and second modular manufacturing stations118 and 160, is characterized as having a separate articletransportation device 122 that allows each carrier 164 to moveindependently through the respective station. The control system 220coordinates the independent movements occurring at each station 18, 20,22, 24, 26, and 28 and synchronizes the transfer of each carrier 164 toa contiguous one of the modular manufacturing stations to define oneoverlying process flow for the manufacturing chain 10.

It should be understood that the above description is intended forillustrative purposes only, and is not intended to limit the scope ofthe present disclosure in any way. Thus, those skilled in the art willappreciate that other aspects of the disclosure can be obtained from astudy of the drawings, the disclosure and the appended claims.

1. A material handling system, comprising: a composite beam including anupper rail and a lower track connected through a plurality of spacedapart transverse members, the lower track defining two parallelchannels; a trolley having an upper set of wheels and a lower set ofwheels, the lower set of wheels received within the two parallelchannels; a drive tube positioned between the upper rail and the lowertrack such that the upper set of wheels are in frictional engagementwith the drive tube; and a drive system configured to rotate the drivetube.
 2. The material handling system of claim 1, wherein each of theplurality of transverse members includes an inverted U-shapedcross-section defining a pair of free ends, each of the pair of freeends supporting a C-shaped channel of the lower track.
 3. The materialhandling system of claim 2, wherein the upper rail includes a T-shapedcross-section defining a central web and a transverse flange, thecentral web being received within a vertically aligned slot of an upperportion of each of the plurality of transverse members.
 4. The materialhandling system of claim 2, wherein the upper rail includes a pair ofoppositely oriented structural members, each of the pair of oppositelyoriented structural members having a vertically oriented web secured toeach of the plurality of transverse members.
 5. The material handlingsystem of claim 4, further including a horizontally aligned supportplate secured to each of the pair of free ends of the plurality oftransverse members.
 6. The material handling system of claim 1, furtherincluding at least one cable tray supported from or within the compositebeam.
 7. The material handling system of claim 1, further including afirst load bar pivotably supported from a first trolley assembly.
 8. Thematerial handling system of claim 7, further including a second load barpivotably supported from a second trolley assembly, and a carrier havinga first end pivotably supported from the first load bar and a second endpivotably supported from the second load bar.
 9. The material handlingsystem of claim 1, further including a plurality of drive tubespositioned in series, each of the plurality of drive tubes beingindependently driven by an electric drive motor.
 10. The materialhandling system of claim 9, further including a track switch positionedbetween two of the plurality of drive tubes, the track switch includinga movable track assembly that is movable between a first positiondefining a first path and a second position defining a second path. 11.The material handling system of claim 1, further including avariable-frequency drive and a predetermined length of cable supportedfrom the composite beam.
 12. A method of operating a material handlingsystem, comprising: transporting a trolley having an upper set of wheelsand a lower set of wheels along the material handling system, at leastin part, by: supporting the lower set of wheels of the trolley withintwo parallel channels defined by a lower track; frictionally engagingthe upper set of wheels of the trolley with a drive tube; rotating thedrive tube to move the lower set of wheels within the two parallelchannels; and supporting a weight carried by the trolley with acomposite beam including an upper rail and the lower track connectedthrough a plurality of spaced apart transverse support members.
 13. Themethod of claim 12, wherein the transporting step includes distributinga weight carried by a first carrier between at least a first trolley anda second trolley.
 14. The method of claim 13, wherein the transportingstep further includes continuously engaging at least one of the firsttrolley and the second trolley with one of a plurality of drive tubes.15. The method of claim 14, wherein the transporting step furtherincludes transporting the first carrier around a curve, at least inpart, by: engaging the second trolley with a first drive tube;disengaging the first trolley from the first drive tube; pushing thefirst trolley around the curve using the second trolley; engaging thefirst trolley with a second drive tube; disengaging the second trolleyfrom the first drive tube; and pulling the second trolley around thecurve using the first trolley.
 16. The method of claim 15, wherein thetransporting step further includes stopping the first trolley and thesecond trolley when the first carrier is positioned about the curve suchthat ends of the first carrier extend beyond a perimeter defined by thecurve.
 17. The method of claim 16, wherein the transporting step furtherincludes removing the first carrier from the first trolley and thesecond trolley using a transfer device when the first trolley and thesecond trolley are stopped.
 18. The method of claim 14, wherein thetransporting step further includes: transporting the first carrier alonga first path; actuating a first track switch positioned between two ofthe plurality of drive tubes; and transporting the first carrier throughthe first track switch and along a second path having an angle greaterthan zero with respect to the first path.
 19. The method of claim 18,wherein the transporting step further includes: transporting the firstcarrier along the second path past the first track switch and in aforward direction; actuating at least a second track switch; andtransporting the first carrier through the second track switch and alonga third path in a reverse direction.
 20. The method of claim 18, whereinthe transporting step further includes changing a sequence of the firstcarrier and a second carrier, at least in part, by: maintaining thefirst carrier on the second path; actuating the first track switch; andtransporting the second carrier along the first path past the firsttrack switch.